Training module

on

Problem
Solving Tools
1
What are 7 QC Tools ?
QC tools are the means for Colleting
data , analyzing data , identifying root causes
and measuring the results.
THESE TOOLS ARE RELATED TO
Numerical DATA processing

USER HAS TO ARRIVE AT THE

SOLUTION & IMPLEMENT
2
Problem Solving Tools

1. Simple Tools for Problem Analysis

1.1 Why -Why Analysis
1.2 What If Analysis
2 Simple 7 QC Tools (Statistical Tools)
•Stratification
•Pareto Diagram
•Cause and Effect Diagram
•Check Sheet
•Control Chart/Graph
•Histogram
•Scatter Diagram
Problem Solving Tools
What is a “Problem “?
“Problem is an undesirable event” or ..

Any Gap between what is expected and what is

obtained , can be called as a Problem, and any effort to
reduce this gap can be called as “Problem Solving”

Expected
(Gap ?) A Problem!

Obtained
Problem Solving Tools
Symptoms and the Root Causes
An undesirable end result is only a starting point
or Symptom.

Eg: When an equipment breaks down , It is an end

result or a Symptom of a Problem.

The abnormalities present in the responsible factors , are

referred to as root cause(s) of the problem
Problem Solving Tools
Four types of Problems
Problem Solving Tools
Why - Why
Library analysisSolving
of Problem - An Example
Tools

Purpose : It is the simple tool used by the team

/observer to find out the cause of the
problem/Accident/ Breakdown at the Workplace.

Many times, the root cause of the problem can be

identified by asking Why 5 times and the repetition of such
problems can be prevented by taking countermeasure
immediately.
Problem Solving Tools
Why - Why
Library analysisSolving
of Problem - An Example
Tools
Water Dripping in Substation 1
WHY ?
Water accumulated at the roof
WHY ?
Outlet drain chocked
WHY ?
Atmospheric dust & dirt
WHY ?
Periodic cleaning of drain not done
Action

Proper scheduled procedure for roof cleaning is to be prepared

Problem Solving Tools
Why - Why
Library analysisSolving
of Problem - Example-2
Tools
WHY WHY ANALYSIS ( ACCIDENT )
JANUARY’2001

LOCATION :- WOOL COMBING ACCIDENT

OCCURRED TO SRI K.N.PAUL

PROBLEM : Right hand fingers got

seriously injured

WHY ?

While fitting feed roller spiked

rings, his RH fingers got pressed
with the F/Roller
Problem Solving Tools
Why - Why
Library analysisSolving
of Problem - Example-2
Tools (Contd..)
WHY ?
The F/R shaft was lifted from the m/c & placed about 2 ft.high
from the floor by means of a chain-pulley block & a supporting
device. Suddenly the belt fastener got slipped off causing the
feed roller to fall down
WHY ?

Since the job was being done for the first time,proper
fastening device suitable for the spiked feed roller could not
be designed

ACTION

Development of suitable fastening device being contemplated

and to be adopted for a repetitive jobs
Problem Solving Tools
What-IfofAnalysis
Library Problem Solving Tools

Purpose : It is the simple Pro active tool

used by the team / observer, to identify
problems before hand and take appropriate
counter measures to prevent such problems .
Problem Solving Tools
What-IfofAnalysis
Library Problem- Solving
An Example
Tools
Area : Equipment :Compressor
Team :
SL. What If Results Countermeasures
1. There is no Water in The Engine heats • Inspect the
the Radiator of an up and Piston may Temperature of
Automobile ? And it get seized. outlet water .
is not noticed. • Provide the temp.
Indictor for the
driver
Pareto Diagram
1. What is Pareto diagram ?
A Pareto diagram is a combination of bar and line graphs of
accumulated data, where data associated with a problem
(e.g., a defect found, mechanical failure, or a complaint
from a customer) are divided into smaller groups by cause
or by phenomenon and sorted, for example, by the number
of occurrences or the amount of money involved. (The
name “Pareto” came from an Italian mathematician who
created the diagram.)

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Pareto Diagram
2. When is it used and what results will be obtained?

Please refer to the table on next slide for the

usage and benefits of a Pareto diagram. It is
mainly used to prioritize matters, and because
of its easiness of use, the diagram is used in a
wide variety of fields.

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Pareto Diagram
Method Usage Result
Used to identify and
Allowsclarification of
prioritize a problem.
Pareto Diagram important tasks.
(No. of Occurrences) Used to review the effects of Allows identification of
an action taken. a starting point (which
task to start with).
Allows projection of
Used to prioritize actions. the effects of a measure
(Used during phases to to be taken
monitor the situation,
analyze causes, and review
effectiveness of an action.)

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Pareto Diagram
Example

Assessment using Pareto Confirmation of Effect

diagram (prioritization) (Comparison)
To identify a course of
action to be emphasized Frequently used to check
using a variety of data. the effect of an
improvement.
Details of “ A”

Improved

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Cause & Effect Diagram
1. What is Cause & effect Diagram ?
A cause and effect diagram is “a fish-bone diagram that
presents a systematic representation of the relationship
between the effect (result) and affecting factors (causes).”
Solving a problem in a scientific manner requires
clarification of a cause and effect relationship, where the
effect (e.g., the result of work) varies according to factors
(e.g., facilities and machines used, method of work,
workers, and materials and parts used). To obtain a good
work result, we must identify the effects of various factors
and develop measures to improve the result accordingly.

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Cause & Effect Diagram
2. When is it used and what results will be obtained?

A cause and effect diagram is mainly used to study

the cause of a certain matter. As mentioned above,
the use of a cause and effect diagram allows
clarification of causal relation for efficient problem
solving. It is also effective in assessing measures
developed and can be applied to other fields
according to your needs.

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Cause & Effect Diagram
Method Usage Result
Can obtain a clear
Used when
overall picture of causal
Cause and Effect clarifying a cause relation. (A change in
Diagram
Machine Man
and effect the cause triggers a
relationship.[Used variation in the
Effect

during a phase to result.)○ Can

analyze causes.] clarify the cause and
Material Method
effect relationship.
Cause (4M’s) Result
(Controlled State)
Used to develop
Can list up all causes
countermeasures.
to identify important
causes.
[Used during a phase to plan
countermeasures.] Can determine the
direction of action
(countermeasure).

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Cause & Effect Diagram
Mechanism of Quality of
Copying Machine Copying Paper
Malfunction of
Running out
Smudges on the the roller
of stock

Many Copying Errors!

copied surface
Printing too Too thin
Internal devices not lightly
working smoothly Dampened
Folded

Deterioration of
Error in
performance due
Keyboard handling placement of Dirt on the
to high
error paper (setting glass
temperatures
its face up) surface
Error in selecting a
Dust
scale of reduction Error in Nicotine-
selecting stained
shading
User Surrounding
Environment

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Stratification
1. What is Stratification ?

Stratification means to “divide the whole into smaller portions

according to certain criteria.” In case of quality control,
stratification generally means to divide data into several groups
according to common factors or tendencies (e.g., type of defect
and cause of defect).
Dividing into groups “fosters understanding of a situation.”
This represents the basic principle of quality control.

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Stratification
2. When is it used and what results will be obtained?
The “common and basic principle” of quality control is
stratification, i.e., to think a matter out by breaking it
into smaller portions. Stratification has a number of
useful purposes. The table below shows only a few
examples of these purposes.

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Stratification
Method Usage Result
Grouping by day, •Used to observe variations
•Allows observation
time, place, among strata.
worker, or •Used to identify the
of variations among
process strata.
relationship between cause
•By performing a
Number of Units
and effect.
•Used to identify a purpose
cause analysis using
X ★★★★★★★
the stratified data,
Y △△△△ and means to serve the
the following can be
purpose
Z ○○○
[Used during phases to monitor accomplished.
the situation, analyze causes, 1.Identification and control of a
review effectiveness of an action, problem
perform standardization, and 2.“Division of data (obtained by
implement a selected control using each QC tool) into several
measure.] groups”

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Stratification
Item Method of Stratification
Hour, a.m., p.m., immediately after start of work,
Elapse of time
shift, daytime, nighttime, day, week, month
Worker, age, male, female, years of experience,
Variations among workers
shift, team, newly employed, experienced worker
Processing method, work method, working
Variations among work
conditions (temperature, pressure, and speed),
methods
temperature
Variations among Measurement tool, person performing
measurement/inspection measurement, method of measurement, inspector,
methods sampling, place of inspection

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Check Sheet
1. What is Check sheet ?
A check sheet is “a sheet designed in advance to allow easy
collection and aggregation of data.” By just entering check
marks on a check sheet, data can be collected to extract
necessary information, or a thorough inspection can be
performed in an efficient manner, eliminating a possibility
of skipping any of the required inspection items.
A check sheet is also effective in performing stratification
(categorization).

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Check Sheet
2. When is it used and what results will be obtained?

Please refer to the table on next slide for the usage

and benefits of a check sheet. It is frequently used in
daily business operations, often not specifically for
QC purposes.

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Check Sheet
Method Usage Result
Used to collect Ensures collection of
Check Sheet data. required data.
Day
Process Used when Allows a thorough
Process 1
performing a inspection of all check
Process 2

thorough items.
Process 3

inspection. Can understand

Used during phases to monitor tendencies and
the situation, analyze causes, variations.
review effectiveness of an Can record required
action, perform data.
standardization, and
implement a selected control
measure

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Check Sheet
A check sheet used to identify defects

Date
Total
Defect

Vertical Scratch

Scratch

Dent

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Control Chart (Control Chart / Graph 1)
1. What is Control Chart ?
A control chart is used to examine a process to see if
it is stable or to maintain the stability of a process.
This method is often used to analyze a process. To
do so, a chart is created from data collected for a
certain period of time, and dots plotted on the chart
are examined to see how they are distributed or if they
are within the established control limit. After some
actions are taken to control and standardize various
factors, this method is also used to examine if a
process is stabilized by these actions, and if so, to
keep the process in a stable state.
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Control Chart
2. When is it used and what results will be obtained?
There are two types of control charts: one used for
managerial purposes and the other for analytical
purposes. A control chart is used to identify dots that
are outside the control limit, which indicate some
anomalies in a process. In addition, seven
consecutive dots showing values that are below or
above the mean (central) value, or an increasing or a
decreasing trend represented by seven consecutive
dots also indicate “a problem in a process.”

We need to examine what has caused such a

tendency.
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Control Chart
Method Usage Result
Used to observe a Can identify a change
Control Chart
caused by elapse of
change caused by
time.
elapse of time.
Can judge the
[Used during phases to
process if it is in its
monitor the situation,
normal state or there
x-R Control Chart analyze causes, review
are some anomalies
effectiveness of an
by examining the dots
action, perform
plotted on the chart.
standardization, and
implement a selected In the example “x bar ” -R
control chart, “X bar”
control measure represents the central value,
while “R” indicates the range.
Control Chart for Managerial Purposes: Extends the line indicating the control limit used for analytical purposes
to plot data obtained daily to keep a process in a good state.
Control Chart for Analytical Purposes: Examines a process if it is in a controlled state by collecting data for a
certain period of time. If the process is not controlled, a survey is performed to identify its cause and develop
countermeasures.

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Control Chart
Examples of Values
Represented by Dots
Values above the
control limit
represented
seven by
seven
Consecutive dots

Control
x- Chart
A decline
represented
representedbyby
seven

consecutive dots

Group Number
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Graph
1. What is Graph ?

A graph is “a graphical representation of data, which allows a

person to understand the meaning of these data at a glance.”
Unprocessed data simply represent a list of numbers, and
finding certain tendencies or magnitude of situation from these
numbers is difficult, sometimes resulting in an interpretational
error. A graph is a effective means to monitor or judge the
situation, allowing quick and precise understanding of the
current or actual situation.
A graph is a visual and summarized representation of data that
need to be quickly and precisely conveyed to others.

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Graph
2. When is it used and what results will be obtained?
A graph, although it is listed as one of the QC tools, is
commonly used in our daily life and is the most
familiar means of assessing a situation.

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Graph
Method Usage Result
120
Changes in a time-sequential Can observe changes in
100

80 order – line graph a time-sequential order,

60 East ratios, and amounts.
40

20 Amounts – bar graph, etc.

0 A graph is the most
1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

Ratios – pie graph, band frequently used tool to

chart, etc. examine the various
4th Qtr
13%
1st Qtr
13% matters such as those
2nd Qtr
17%
(The items listed above are listed on the left.
representative examples.)
3rd Qtr
57%

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Graph
[ Bar Graph of Sales] [Band Chart of Expenses]
・ Survey Period: Dec. 1999
million) ( ¥ million)
・ Prepared by: M/T

million)

Before
Sales

Chemicals Oils Electricity

Taking
(430) (200) (170)
Actions
( Total: ¥ 8 million)

After Chemicals Oils

Taking (240) (150)
Actions
(TTotal:
otal: 4.95
¥ 4.95 million)
million)

Sales AIwate BTokyo COsaka DShizuoka Electricity

Office (108)

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Histogram
1. What is Histogram ?

When creating a histogram, “a range of data is divided into

smaller sections having a uniform span,and the number of data
contained in each section (the number of occurrences) is
counted to develop a frequency distribution table.” Then, “a
graph is formed from this table by using vertical bars, each
having the height proportional to the number of occurrences in
each section.”

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Histogram
2. When is it used and what results will be obtained?
A histogram is mainly used to analyze a process by
examining the location of the mean value in the
graph or degree of variations, to find a problem point
that needs to be improved. Its other applications are
listed in the table below.

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Histogram
Method Usage Result
•Used to assess the actual
conditions. •Can identify the
Histogram •Used to analyze a process to location of the mean
Standard
Range identify a problem point that needs (central) value or
to be improved by finding the degree of variations.
location of the mean value or •Can find out the scope
degree of variations in the graph.
•Used to examine that the target
of a defect by inserting
X Axis (Values
Actually quality is maintained throughout standard values.
Range of
Variations
Measured)
the process. •Can identify the
•Others condition of
[Used during phases to distribution (e.g.,
monitor the situation, analyze whether there is an
causes, and review isolated, extreme
effectiveness of an action.] value).

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Scatter Diagram
1. What is Scatter Diagram ?

A scatter diagram is used to “examine the relationship between

the two, paired, interrelated data types, ” such as “height and
weight of a person.” A scatter diagram provides a means to
find whether or not these two data types are interrelated. It is
also utilized to determine how closely they are related to
identify a problem point that should be controlled or improved.

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Scatter Diagram
2. When is it used and what results will be obtained?
The table on next slide shows some examples of
scatter diagram’s usage. If, for example, there is a
relationship where “an increase in the number of
rotations (x) causes an increase in abrasion (y),” there
exists “positive correlation.” If, on the other hand, the
existence of a relationship where “an increase in the
number of rotations (x) causes a decline in abrasion
(y)” indicates that there is “negative correlation.”

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Scatter Diagram
Method Usage Result
•Used to identify a relationship •Can
Scatter Diagram identify cause
between two matters.
ｙ Axis
•Used to identify a relationship and effect relation.
Abrasion

between two matters and establish •Can understand the

countermeasures based on their
cause and effect relation. relationship
x Axis Example Usage between two
Number of
Rotations
1.Relationship between thermal results.
treatment temperature of a steel
material and its tensile strengths
2.Relationship between visit made
by a salesman and volume of sales
3.Relationship between the number
of persons visiting a department
store and volume of sales
4 Others
[Used during phases to monitor the
situation, analyze causes, and review
effectiveness of an action.]
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Scatter Diagram

ｙ Axis
Abrasion (micron)

x Axis
Number of
Rotations

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 Application of QC tools in Problem Solving
Graphs Check Stratifi Pareto Cause & Histogra Scatter Control
sheet cation Diagra Effect m Diagram Chart
m Diagram
Identification of
problem
Defining the
problem
Record of facts

Detecting causes of
problem
Develop
Improvement
method
( Solution )
Implementation

Evaluation of result

Process control
( Standardization )

Relation :- 44
Strong Normal
To sum up 7 QC tools (Numerical data ) are used as follow:

• Stratification Basic processing performed when

collecting data
• Pareto Diagram To identify the current status and issues
• Cause and Effect Diagram
To identify the cause and effect relationship
• Histogram To see the distribution of data
• Scatter Diagram To identify the relationship between two
things
• Check Sheet To record data collection
• Control Chart/Graph To find anomalies and identify the current
status

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Thank you
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